Instruction Manual for 22T Primary Drive Gear

Part Detail

Item No.：０２―０１−０３０４

Applicable models and frame Nos:

 KAWASAKI KSR110

 SUZUKI DR-Z110

 dealer.

COPY

Features

(models from 2003 onwards)

：KL110A-000001∼

：KL110A-A08133∼

・Thank you for purchasing one of our TAKEGAWA's products. Please strictly follow the following instructions in installing and usingthe kit.

・Before fitting the kit, please be sure to check the part contents. Should you have any questions about the products, please kindly contact your local motorcycle

Installation Procedures

１．Referring to the service manual, detach the primary clutch.

Primary drive gear

Part Name

○The light weight reduces the load on the crank shaft and improves the throttle response, as the stock primary clutch is removed, with only gear left.

○Since the transmission is not through the clutch, crank shaft rotation is 100% transmitted to the secondary clutch, preventing loss of power.

(At your option)

Please read the following before starting the installation

２．From the clutch housing, remove a clutch holder, clutch holder spring, ring

  and clutch gear.

Clutch gear

◎We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions in the manual.

◎We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation

 and use of the products.

◎This kit is designed for exclusive use in the above-mentioned applicable models and frame numbers only. Please take note that this kit cannot be mounted on

 other models.

◎This product contains a gear only. Gaskets, etc., necessary for disassembly, are not included, which please purchase separately.

◎Do the disassembly and installation work correctly referring to the relative genuine service manual for the above-mentioned applicable models. Those who

 are technically unskilled or inexperienced are required not to do the work. Improper installation because of insufficient skill and knowledge could lead to parts

 breakage. Therefore, we recommend those who are technichally inexperienced or do not have enough tools to ask a technically-reliable specialist shop for

 the work.   

◎Always use new bolts, nuts, dowel pins and packings. Never reuse severely worn-out or damaged ones.

◎Be sure never to use this gear in combination with other manufacturer’s products. There is a possibility that parts may be damaged. And we shall be held  

 harmless against any breakage or damage of any part caused by the use of this product in combination with other manufacturer’s products.

◎You are kindly requested not to contact us about the combination of our products with other manufacturers'.  

◎Installation of this drive gear alone does not work. Installation of our TAKEGAWA’s hydro clutch conversion kit (Item No. 02-01-0292) along with this gear is

 essential.

◎Please note that this gear cannot be installed onto KLX110 / DR-Z110 for the year 2002 because of the difference in the gear shape.

◎In installing this product, removal of the genuine clutch gear is necessary. As this clutch gear is intended to reduce the backlash on the primary side, no  

 installation of the clutch gear does not affect the clutch operation. You can use this product withuot installing the clutch gear.

◎Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications and prices are subject

 to change without prior notice.

◎This manual should be retained for future reference.

(At your option)

３．Install the removed parts to the drive gear.

 ●Install the clutch gear to the drive gear.

 ●Install the holder spring to the clutch holder.

 ●Press the clutch holder into the drive gear, meshing the teeth together.

 ●Put a mark on any random tips of teeth meshing together.

(In case the clutch gear is installed)

４．Give the clutch gear 2-tooth turns clockwise, and attach the drive gear to the

  crank shaft.

※At this point, check that the marks on the cog tips are off the original positions.

(In case the clutch gear is NOT installed)

Ring

Clutch holder spring

Clutch holder

Caution

The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions.

・Make sure the bike is secure on the sidestand on level ground for safety’s sake during installation.

・Work only when the engine and muffler are cool. (Otherwise, you will burn yourself.)

・Do the installation work using the proper tools for the work. (Otherwise, the installation with improper tools could cause breakage of parts or injuries

 to yourself.)

・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque. (Improper torque could cause these parts to get   

 damaged or fall off, resulting in accidents.)

・As some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)

・Before riding, always check every section for slack in parts like screws. If you find slack ones, screw them securely up to the specified torque.    

 (Otherwise, improper tightening may cause parts to come off.)

 Attach the drive gear to the crank shaft.

５．Attach a nut to the crank shaft, and tighten the nut to the specified torque,  

  holding the drive gear tight to prevent it from rotating.

  Torque : 72 N・m (7.3 kgf・m)

Primary clutch housing

Qty

1

Warning

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions.

・When you notice something abnormal with your motorcycle while riding, stop riding immediately and park your motorcyle in a safe place.

 (Otherwise, the abnormality could lead to accidents.)   

・Before doing work, make sure your bike is secure on level ground for safety's sake. (Otherwise, your motorcycle could overturn and injure you while

  you are working.)

・Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.

 (Improper checking or maintenance could lead to accidents.)

・If you find damaged parts when checking and performing maintenance, do not use these parts any longer, and replace them with new ones.

 (The continued use of these damaged parts could lead to accidents.)

・Keep plastic bags for packing products out of children's reach, or discard them. (Otherwise, there is a danger of their suffocating if they get it on.)

・Always start the engine in a well-ventilated place, and do not turn the engine on in an airtight place.

 (Otherwise, you will suffer from carbon monoxide poisoning.)

  of removal.

Drive gear

Nut

3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan

TEL : 81-721-25-1357 FAX : 81-721-24-5059

URL : http://www.takegawa.co.jp